Front Suspension Crossmember Replacement. Chevrolet PJJ 2000

For 1990-2009 cars

### Removal Procedure

1. Raise the vehicle on a hoist. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the splash shields. Refer to Splash Shield Replacement - Wheelhouse in Body Front End.
4. Remove the engine strut from the lower engine mount and frame. Refer to Engine Mount Strut Replacement in Engine Mechanical 2.4L.
5. Remove the front exhaust pipe. Refer to Intermediate Pipe Replacement (2.4L) in Engine Exhaust.
6. Disconnect the antilock brake system (ABS) harness from the wheel speed sensor and front suspension crossmember. Refer to Wheel Speed Sensor Replacement (Front) in Antilock Brake System.
7. Remove the lower pinch bolt from the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
8. Remove the ball joints from the steering knuckles. Refer to Stabilizer Shaft Replacement.
9. Remove the tie rods from the steering knuckles. Refer to Tie Rod End Replacement - Outer - On Vehicle in Power Steering System.
10. Remove the brake lines from the retainers on the front suspension crossmember. Refer to Brake Hose Replacement-Front in Hydraulic Brakes.
11. Remove the power steering hoses from the power steering gear. Refer to the following procedures:

• | Power Steering Pressure Hose Replacement (2.4L)

• | Power Steering Return Hose Replacement (2.4L)

12. Remove the front suspension support brace. Refer to Front Suspension Support Brace Replacement.
13. Lower the vehicle until the front suspension crossmember rests on jack stands.
14. Remove the front suspension crossmember mounting bolts.
15. Raise the vehicle off of the front suspension crossmember.
16. Remove the following components if replacing the front suspension crossmember:

• | The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.

• | The power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.

### Installation Procedure

1. Install the following components on the front suspension crossmember, if removed:

• | The lower control arms. Refer to Lower Control Arm Replacement in Front Suspension.

• | The power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.

2. Lower the vehicle on to the front crossmember support.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the front suspension crossmember mounting bolts.

Tighten

1. Tighten the left rear outboard bolt to 110 N·m (71 lb ft).
2. Tighten the right rear outboard bolt to 110 N·m (71 lb ft).
3. Tighten the front upper bolt to 110 N·m (71 lb ft).
4. Tighten the rear inboard bolts to 110 N·m (71 lb ft).

4. Install the front suspension support brace. Refer to Front Suspension Support Brace Replacement.
5. Install the power steering hoses to the power steering gear. Refer to the following procedures:

• | Power Steering Pressure Hose Replacement (2.4L)

• | Power Steering Return Hose Replacement (2.4L)

6. Install the brake lines to the retainers on the front suspension crossmember. Refer to Brake Hose Replacement-Front in Hydraulic Brakes.
7. Install the tie rods to the steering knuckle. Refer toTie Rod End Replacement - Outer - On Vehicle in Power Steering System.
8. Install the ball joints to the steering knuckles. Refer to Lower Ball Joint Replacement.
9. Install the lower pinch bolt to the steering gear. Refer to Intermediate Steering Shaft Replacement in Steering Wheel and Column - Tilt.
10. Connect the ABS harness to the wheel speed sensor and frame. Refer to Wheel Speed Sensor Replacement (Front) in ABS.
11. Install the front exhaust pipe. Refer to Intermediate Pipe Replacement (2.4L) in Engine Exhaust.
12. Install the engine strut to the lower engine mount and frame. Refer to Engine Mount Strut Replacement in Engine Mechanical - 2.4L.
13. Install the splash shields. Refer to Splash Shield Replacement - Wheelhouse in Body Front End.
14. Install the tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
15. Bleed the power steering system. Refer to Bleeding Power Steering System in Power Steering System.
16. Align the front wheels. Refer to Measuring Wheel Alignment (Front) in Wheel Alignment.